Method and system for portioning workpieces to user-scanned shape and other specifications

ABSTRACT

A method and system are provided for automatically portioning workpieces, such as food products, into both shape and other user-defined specification(s). Workpieces are portioned both to shape and weight, such as to a weight-specific uniform shape, by adjusting (e.g., scaling up and down or slightly modifying) a desired template shape until the desired weight is achieved depending on the varying thickness of each workpiece. For example, from a thicker workpiece, a smaller-sized piece having a predefined shape and weight is portioned, while from a thinner workpiece, a larger-sized piece having the same predefined shape and weight is portioned. The system permits a user to scan in and edit a desired (reference) shape to be used as a template in the portioning process.

CROSS-REFERENCE TO RELATED APPLICATION

This application is based on, and claims priority from, U.S. ProvisionalApplication No. 60/535,354, filed Jan. 9, 2004.

FIELD OF THE INVENTION

The present invention relates generally to processing workpieces such asfood products, and more specifically, to portioning workpieces intopieces having a user-scanned shape, while also considering one or moreother specifications such as weight and size.

BACKGROUND OF THE INVENTION

Workpieces, including food products, are portioned or otherwise cut intosmaller pieces by processors in accordance with customer needs. Also,excess fat, bone, and other foreign or undesired materials are routinelytrimmed from food products. It is usually highly desirable to portionand/or trim the workpieces into uniform sizes, for example, for steaksto be served at restaurants or chicken fillets used in frozen dinners orin chicken burgers. Much of the portioning/trimming of workpieces, inparticular food products, is now carried out with the use of high-speedportioning machines. These machines use various scanning techniques toascertain the size and shape of the food product as it is being advancedon a moving conveyor. This information is analyzed with the aid of acomputer to determine how to most efficiently portion the food productinto optimum sizes. For example, a customer may desire chicken breastportions in two different weight sizes, but with no fat or with alimited amount of acceptable fat. The chicken breast is scanned as itmoves on an infeed conveyor belt and a determination is made through theuse of a computer as to how best to portion the chicken breast to theweights desired by the customer, with no or limited amount of fat, so asto use the chicken breast most effectively.

Portioning and/or trimming of the workpiece can be carried out byvarious cutting devices, including high-speed liquid jet cutters(liquids may include, for example, water or liquid nitrogen) or rotaryor reciprocating blades, after the food product is transferred from theinfeed to a cutting conveyor. Once the portioning/trimming has occurred,the resulting portions are off-loaded from the cutting conveyor andplaced on a take-away conveyor for further processing or, perhaps, to beplaced in a storage bin.

Portioning machines of the foregoing type are known in the art. Suchportioning machines, or portions thereof, are disclosed in priorpatents, for example, U.S. Pat. Nos. 4,962,568 and 5,868,056, which areincorporated by reference herein. Typically, the workpieces are firstcarried by an infeed conveyor past a scanning station, whereat theworkpieces are scanned to ascertain selected physical parameters, forexample, their size and shape, and then to determine their weight,typically by utilizing an assumed density for the workpieces. Inaddition, it is possible to locate discontinuities (including voids),foreign material, and undesirable material in the workpiece, forexample, bones or fat in a meat portion.

The scanning can be carried out utilizing a variety of techniques,including a video camera to view a workpiece illuminated by one or morelight sources. Light from the light source is extended across the movingconveyor belt to define a sharp shadow or light stripe line. When noworkpiece is being carried by the infeed conveyor, the shadow line/lightstripe forms a straight line across the conveyor belt. However, when aworkpiece passes across the shadow line/light stripe, the upper,irregular surface of the workpiece produces an irregular shadowline/light stripe as viewed by a video camera directed downwardly at anangle on the workpiece and the shadow line/light stripe. The videocamera detects the displacement of the shadow line/light stripe from theposition it would occupy if no workpiece were present on the conveyorbelt. This displacement represents the thickness (or height) of theworkpiece. The width of the workpiece is determined by the width of theirregular shadow line/light stripe. The length of the workpiece isdetermined by the length of belt travel that shadow lines/light stripesare created by the workpiece. In this regard, an encoder is integratedinto the infeed conveyor, with the encoder generating pulses at fixeddistance intervals corresponding to the forward movement of theconveyor.

The data and information measured/gathered by the scanning devices aretransmitted to a computer, typically on board the portioning apparatus,which records the location of the workpiece on the conveyor as well asthe shape and other parameters of the workpiece. With this information,the computer determines how to optimally cut or portion the workpiece atthe portioning station, and the portioning may be carried out by varioustypes of cutting/portioning devices.

Automatic portioning systems of food products, such as boneless chickenbreasts, should be capable of cutting the products into uniform shape,weight, and other specifications as provided by their users. Oftentimes,the users have finished samples that exemplify the users' particularneeds, such as a sample having a desired shape.

Some conventional portioning systems use fixed forms to portion productsinto a specific shape. A form is like a cookie cutter that is used tostamp out a particular shape, and then the cut piece is trimmed to adesired thickness by various types of knives. The use of forms iscumbersome, in that each form is usable to stamp out only one shape, andthus many forms are required for stamping out various shapes. Also, eachform stamps out pieces only to a particular shape, without considering,for example, the resulting weight. Hand cutting is also available forportioning food products into particular shapes, but cutting theproducts into both uniform shape and uniform weight is very difficult.

Accordingly, a need exists for an improved portioning system, which iscapable of cutting workpieces to a specific shape, and of growing,shrinking, or otherwise altering the shape in order to achieve one ormore additional specifications such as weight. Preferably, such aportioning system permits a user to readily define the particular shape,and any other specification, to which workpieces are to be portioned.

SUMMARY OF THE INVENTION

According to one aspect, the present invention is directed to anautomatic portioning system to portion workpieces, which may havevarious thicknesses, into a weight-specific uniform shape, such as intoportions having both a specific weight and a specific shape, and whichthus may be of varying two-dimensional areas, or sizes (width×length),depending on the varying thickness of each workpiece. In variousexemplary embodiments, this is achieved by scaling up or down a templatehaving a specific shape on the workpiece until the desired weight isachieved. The scaled up/down template then becomes the cutting path forthe workpiece. In some applications, the weight and shape requirementsmay be relaxed and the workpieces may be cut into portions havingapproximate weight and shape within user-specified ranges.

According to another aspect of the present invention, the automaticportioning system may portion workpieces into approximate weight andshape, and further within a user-specified range of area, or sizes(width×length).

According to yet another aspect of the present invention, the automaticportioning system may portion workpieces into size-specific shape, suchas portions having a specific size (or size range) and a specific shape(or shape range), and thus may be of a varying weight depending on thevarying thickness of each workpiece.

In any of the various embodiments of the present method summarizedabove, workpieces are cut into portions, each having a specific orapproximate shape as predefined by the user, while also satisfying oneor more other specifications. In other words, the present inventionachieves completely automatic “shape” cutting. Although the methods areof particular use in the context of cutting or portioning foodstuffs inthe food products industries, and are described herein relative to suchapplication, their use is not limited to this particular application.

According to a further aspect of the present invention, a method ofportioning products involves not only portioning workpieces according toshape and one or more other specifications, but also ensuring that theresulting product has desirable characteristics that are not directlycontrolled by the portioning process. For example, the method simulatesportioning a workpiece to a specific shape and weight A or to the samespecific shape and weight B. The method then calculates the size(width×length) and/or thickness of the piece resulting from cutting tothe specific shape and weight A, or to the specific shape and weight B,respectively. If the resulting size and/or thickness of the pieceportioned to the specific shape and weight A is acceptable, then theworkpiece is cut to weight A. If not, it is determined if the resultingsize and/or thickness of the piece portioned to the specific shape andweight B is acceptable, and if so, the workpiece is cut to weight B. Ifeither cutting to weight A or weight B will not produce an acceptablesize and/or thickness, then no solution exists and no cutting will beperformed.

According to a still further aspect, the present invention permits auser to define the desired (reference) shape into which the workpiecesare to be portioned, by simply scanning in the actual desired shapeusing the portioning system's vision system. Further, the user isallowed to edit the scanned-in shape in digital data form in order todefine a refined shape template to be used in all further processing. Tothis end, the user can interrupt the normal operation of the automaticportioning system at any time to scan in and edit the desired shape. Thedesired shape is stored in computer memory and subsequently used tocontrol the downstream cutting/portioning equipment of the portioningsystem to cut the workpieces into the desired shape.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing aspects and many of the attendant advantages of thisinvention will become more readily appreciated by reference to thefollowing detailed description, when taken in conjunction with theaccompanying drawings, wherein:

FIG. 1A illustrates a system suitable for use in performing a method ofthe present invention, wherein the system is operated in NormalProduction Mode to process (and portion) workpieces (WP);

FIG. 1B illustrates the system of FIG. 1A, which is operated in ShapeScanner Mode to scan in a user-provided reference shape (RS);

FIG. 2 is a flow chart illustrating the overall process for portioningworkpieces into pieces having a specific shape while also meeting anyother user-defined specifications, in accordance with one embodiment ofthe present invention;

FIG. 3 is a flow chart illustrating the routine performed during NormalProduction Mode of the system, in which workpieces are portioned to aspecific shape and weight;

FIG. 4 is a flow chart illustrating the routine performed during NormalProduction Mode of the system, wherein workpieces are portioned into aspecific shape, weight, and size;

FIGS. 5A and 5B illustrate two cut pieces having the same shape andweight, but having different sizes (weight×length) due to thedifferences in thickness;

FIGS. 6A and 6B illustrate two cut pieces, wherein the shape of at leastone of the pieces has been manipulated in a controlled manner so thatthe resulting pieces have the same weight and size, and also havegenerally similar shapes;

FIG. 7 illustrates a butterfly-shaped chicken breast workpiece, fromwhich two half heart-shaped pieces are to be portioned;

FIG. 8A is a sample screen shot, displayed on a monitor of theportioning system according to one embodiment of the present invention,defining a shape cutting path in a connect-the-dots model;

FIG. 8B is a sample screen shot of a shape cutting path, which has beenmodified from that shown in FIG. 8A, by including a notch into the shapeof FIG. 8A;

FIG. 9 is a flow chart illustrating the routine to be performed duringShape Scanner Mode, which is a special case of Shape Input Mode; and

FIG. 10 is a flow chart illustrating a routine for evaluating theeffects of cutting to certain specifications on the final productcharacteristics, which are not directly controlled by the portioningprocess, prior to performing an actual cut, according to a furtheraspect of the present invention.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

FIG. 1A schematically illustrates a system 10 suitable for implementingone embodiment of the present invention. The system 10 includes aconveyor 12 for carrying a workpiece 14 to be portioned thereon, ascanner 16 for scanning the workpiece 14, and a cutter 18 for portioningthe workpiece (WP) 14 into one or more pieces. The conveyor 12, scanner16, and cutter 18 are coupled to, and controlled by, a processor 20.Generally, the scanner 16 scans in the workpiece 14 to produce scanninginformation representative of the workpiece, and forwards the scanninginformation to the processor 20. The processor 20 analyzes the scanninginformation to calculate an optimal cut path to portion the workpiece 14into one or more desirable pieces. Then, the processor 20 controls thecutter 18 to portion the workpiece 14 according to the calculated cutpath. As illustrated, the processor includes an input device 20 a(keyboard, mouse, etc.) and an output device 20 b (monitor, printer,etc.). The present invention is directed generally to a system andmethod for cutting workpieces to a particular or approximate shape,while considering one or more other parameters (e.g., weight, length,width, height, etc.).

In various exemplary embodiments, the portioning system 10 is capable ofoperating in generally two modes: Normal Production Mode and Shape InputMode. Briefly, during Shape Input Mode, a user is prompted to input andperhaps further edit a reference shape (template) to which workpiecesare to be portioned. During Normal Production Mode, the portioningsystem automatically portions workpieces carried on a conveyor intopieces corresponding to the reference shape.

FIG. 2 is a flow chart illustrating the overall process for portioningworkpieces into a specific shape and one or more user-definedparameters, according to one embodiment of the present invention. Instep 23, the portioning system 10 is operating in Normal ProductionMode. Some examples of routines to be performed in Normal ProductionMode will be described in reference to FIGS. 3 and 4 below. In step 24,it is determined whether a user has requested to enter Shape Input Mode.For example, referring additionally to FIG. 1A, the user may request toenter Shape Input Mode by using any suitable input device 20 a, forexample, by clicking on a “Shape Input Mode” icon displayed on themonitor 20 b. If such a request is received, then proceeding to step 25,the system 10 prompts the user to input (and perhaps also to edit) areference shape, into which workpieces are to be portioned. For example,referring to FIG. 7, suppose that butterfly-shaped chicken breastworkpiece 70 is to be portioned to produce one or two half heart-shapedpieces 72. The user may input the reference shape (the half-heart shapein this example) in various ways. For example, the system 10 mayprestore several standard shapes, from which the user can select one asan initial template. Referring to FIG. 8A, suppose that the shape shownin a window 80 was prestored in the system 10 and selected by the user.At this point, a shape input/edit screen 82 shows the outline of theselected shape in the window 80 in a connect-the-dots model. The mainscreen 84 lists the X and Y coordinates of forty-eight (48) points thatdefine the outline of the selected shape. Specifically, listed numbers1-48 each has a pair of numbers, which show the X and Y coordinates ofeach point that forms the outline of the template shape shown in thewindow 80. The first point, which is point O at the lower left corner ofthe shape shown in the window 80, has the X and Y coordinates of (0,0).

At this point, the user may edit the connect-the-dots model in variousways. For example, the user may select the “move this point” icon 83 onthe screen, and select a point, which will then be highlighted (see, forexample, point 7 highlighted in the example of FIG. 8A). At this point,the user may use any of the arrow keys provided in any standard keyboarddevice 20 a to move the selected point in X-Y space. For example,pressing the right arrow once will move the point to the +X direction bya certain increment, while pressing the up arrow once will move thepoint in the +Y direction by a certain increment.

Alternatively, referring to FIG. 8B, the user may select the X or Yvalue of the point the user wishes to edit, and then type in the newvalue directly into the list. For example, in FIG. 8B, the user mayselect the X and Y values of points 20, 21, and 22 by, for example,highlighting a section 85 on the screen, and then directly enter the newX and Y values to the list. As the user enters the new values, the shapeoutlined in the window 80 changes to correspond with the new X and Yvalues of these points. Once all the editing is completed and the useris satisfied with the final shape, the user may select a “save thisshape” icon 86 on the screen to save the reference shape into the systemmemory.

While the above description describes a method of inputting a shape byediting an existing shape selected from a collection of prestoredtemplates, it is also possible to create a new shape “from scratch,” forexample, by defining the X and Y coordinate values of all the points(e.g., points 1-48 in FIGS. 8A and 8B). This process may be preceded bythe user plotting out a desirable shape on graph paper to ascertain Xand Y values of the key points of the shape.

Further alternatively, according to one aspect of the present invention,a reference shape may be simply scanned into the system using thesystem's scanner 16. The method of scanning a reference shape for thepurpose of creating a template will be more fully described below inreference to FIG. 9.

In one embodiment, the user-defined shapes may be stored (for example,up to 10 shapes) in the system memory so that the user can later recallany of the previously defined shapes.

Referring back to FIG. 2, after the reference shape has been entered,edited, and saved by the user, in step 26, the user may be furtherprompted to accent certain points or regions within the reference shape.The user-specified accent points will be used to slightly modify thereference shape (e.g., by moving in or out the accent points) when theshape requirement is not stringent, as will be more fully describedbelow. Then, in step 27, the user is prompted to enter weight and/orother parameters of the final piece to be portioned from the workpiece.For example, the user may specify the maximum and minimum weight valuesfor the final piece, and/or the maximum and minimum values for thelength, width, and/or height (or thickness) of the final piece to beportioned from the workpiece. If the user wishes to portion workpiecesinto an exact weight, the user may set both the maximum and minimumweight values the same. Likewise, if any of the length, width, andheight of the final product has to be at an exact value, the maximum andminimum values for that dimension may be set the same.

In step 28, the user is further prompted to set horizontal and verticaloffsets to be used in cutting a workpiece. The concept of offset isdescribed in detail in FIG. 7. In this case, from the butterfly-shapedchicken breast piece 70, two half heart-shaped pieces 72 are to beportioned. The chicken breast 70 has the keel 73 running along itscenter, which most users typically wish to exclude from the finalproducts. Therefore, the user may set a Y-offset value (“Yoff”), whichis a distance in the Y direction from a keel line 74 to the cuttingstarting point O of the half heart-shape 72, so as to avoid the keel 73.The keel line 74 for each product can be readily ascertained by theprocessor 20 evaluating the image obtained by scanning the workpiece 70.The user may also define an offset in the X direction (“Xoff”), whichrepresents the distance from the trailing edge of the workpiece 70 tothe cutting starting point O of the half heart-shape 72, assuming thatthe workpiece 70 is on a conveyor moving in the direction of an arrow76. The user may define any desirable X and Y offsets, so as to avoidany undesirable areas in each cutting application.

Referring again back to FIG. 2, in step 29, it is determined if the userhas requested to return to Normal Production Mode. If so, the processreturns to step 23 and the system starts to operate in Normal ProductionMode. Otherwise, the system remains in Shape Input Mode, and the usercontinues to input and/or edit the reference shape (step 25) and/ordefine various parameters and offsets (steps 26-28).

According to one aspect, the present invention is directed to anautomatic portioning system to portion workpieces into a weight-specificuniform shape, such as into portions having both specific (e.g.,uniform) weight (or weight range) and a specific (e.g., uniform) shape(or shape range), and therefore may be of varying sizes depending on thevarying thickness of each workpiece. This concept is schematicallyillustrated in FIGS. 5A and 5B. In these figures, both pieces 50 and 52have the same heart shape and also have the same weight; however,because the thickness (height) of the piece 50 is greater than that ofthe piece 52, the size (width×length) of the piece 50 is smaller thanthat of the piece 52. The thickness (height) of each workpiece, whichmay vary amongst multiple workpieces and also within a workpiece itself,is ascertained based on scanning, as described in the background sectionof the present invention above. In some cases, the thickness ofworkpieces may be predefined or known prior to their introduction into asystem of the present invention. Further, the weight of the originalworkpiece, as well as the weight of each piece to be portioned from theworkpiece, is calculated based on the volume, as ascertained fromscanning, as multiplied by the density of the workpiece. The density maybe predefined for each type of workpiece, and further may be updatedbased on the suitable feedback system. For example, referring to FIG.1A, a weighing station 22 may be provided downstream from the cutter 18to actually weigh the pieces (not shown in FIG. 1A) portioned from theoriginal workpiece 14. The processor 20 compares the actual weight ofthe portioned piece with an assumed weight of the piece as previouslycalculated based on its volume and assumed density, and if the twovalues differ by more than a predefined amount, automatically updatesthe assumed density so as to more closely correspond with the actualweight measured at the weighing station 22.

FIG. 3 is a flow chart illustrating a routine performed during NormalProduction Mode, in which workpieces are to be portioned to a specificshape (or shape range) and weight (or weight range). In step 30, theuser requests to enter Normal Production Mode to cut workpieces to shapeand weight. Typically, the system 10 operates in Normal Production Modeby default, but entry into Normal Production Mode may be specified bythe user, for example, after the user completes the operation in ShapeInput Mode. Then, in Normal Production Mode, for each scanned workpiece(step 32), the processor 20 identifies a cutting starting point (seepoint O in FIG. 7) based on the user-defined offsets. As describedabove, the processor 20 can analyze the image of each incoming workpiecescanned in by the scanner 16 to identify the keel or any other landmarkpoints, from which the cutting starting point is to be offset.

In step 34, the system automatically adjusts a template of the referenceshape, previously specified by the user, until the predefined weight isachieved. For example, the template can be scaled up or down, dependingon the varying thickness of each workpiece, in order to achieve uniformweight. This can be accomplished by, for example, proportionatelyvarying the X and Y dimensions of the reference shape on the scanned-inworkpiece (whose thickness and density information is known orascertained) until the desired weight is calculated, while consideringany user-defined offsets and also optionally avoiding undesirableproduct features such as keel, cartilage, defects, bone, and visible fatin the case of chicken and other meat. Alternatively, if the user haspreviously specified that the final product has to have a specificlength, then the shape can be scaled up or down only in the widthdirection (in the Y direction in FIG. 7) without any change in the Xdirection, or if the user has previously specified that the finalproduct has to have a certain width, then the template shape can bescaled up or down only in the length direction (in the X direction)without any change in the Y direction.

Further alternatively, the user may specify the amount and/or type ofchange allowed to the “ratio” between the length and width (e.g.,Length/Width) so as to control the automatic adjustment process of atemplate shape. For example, the user may define that the “Length/Width”ratio may be increased from the ratio L/W of the original templateshape, then the shape will be automatically stretched in the “L”direction disproportionately to any change made in the “W” direction sothat the ratio L1/W1 of the resulting shape is greater than L/W. Asanother example, the user may define that the “Length/Width” ratio maybe decreased from L/W of the original template shape, then the shapewill be squashed in the “L” direction disproportionately to any changemade in the “W” direction so that the ratio L2/W2 of the resulting shapeis less than L/W. These types of automatic shape adjustments result in ashape that is somewhat disproportionately modified from the originaltemplate shape but that still meets a predefined weight requirement.

In some applications, the weight requirements may be relaxed and theworkpieces may be cut into portions having approximate weight within auser-specified range. Likewise, the length and/or width requirements mayalso be relaxed depending on each application.

In step 36, the processor 20 controls the cutter 18 to cut the workpieceaccording to the cutting path determined in step 34 above. Then,optionally in step 37, each cut piece may be weighed, for example, atthe weighing station 22 in FIG. 1A, to see if it meets theuser-specified weight (or weight range), and if not, the system alertsthe user and/or modifies the weight-calculation algorithm used by thesystem, for example, by updating the assumed density of the workpiece.

In some cases, a user desires a workpiece to be cut into onlyapproximate shapes having both uniform weight and uniform size(width×length, measured along the plane of the conveyor) In these cases,the automatic portioning system of the present invention may permit auser to accent certain points or regions of the desired shape, and theseuser-specified points and regions are moved in and out (as opposed tothe entire outline of the shape) until the desired weight is achieved,while also meeting the size requirement and keeping the shape generallythe same as the original shape. FIGS. 6A and 6B schematically illustratethis concept, in which both portions 60 and 61 have the same weight (orweight range) and the same size (or size range) as defined by W×L(width×length). Suppose that the shape of the portion 60 is the originaldesirable shape, with an accent point 64 defined by the user. Supposealso that the portion 61 is thicker than the portion 60, as shown, andthus, to meet the same weight and size (width×length) requirements asthe portion 60, it is necessary to somewhat modify the shape of theportion 61. As illustrated, this can be achieved by moving the accentpoint 64 in, so as to reduce the shape surface area of the portion 61while maintaining the shape generally similar to the original shape.This adjustment method is suitable when the requirements for the weightand size are rather stringent, while the requirements for the shape aresomewhat more relaxed.

FIG. 4 is a flow chart illustrating the routine performed during NormalProduction Mode to cut workpieces into size, weight, and “approximate”shape (the shape is allowed to vary somewhat), as described above inreference to FIGS. 6A and 6B (step 40). In step 41, the height of aslitter (not shown) is set to correspond to the height parameter definedby the user, if any. In step 43, for each scanned workpiece (step 42), acutting starting point to portion out a piece from the workpiece isidentified based on the user-defined offsets. In step 44, a template ofthe reference shape, previously entered by the user, is adjusted bymoving in or out any user-specified accent point(s) or region(s) untilthe predefined weight (or weight range) is achieved, while alsoconsidering any size related parameters (e.g., length, width, etc.). Asbefore, the adjustment process may be carried out while considering theuser defined offsets and avoiding any undesirable product features suchas keel, cartilage, defects, bone, visible fat, etc. In step 45, thesystem then operates the cutter 18 to execute the portioning based onthe adjusted template. In step 46, as before, the actual cut piece maybe weighed to verify if it meets the user-specified weight, for example,by using the weighing station 22 in FIG. 1A. If the cut piece does notmeet the user-specified weight, the user may be notified of the fact,and further, the system may modify its weight-calculation algorithm, forexample by correcting the assumed density of the type of workpieces. Theuse of accent points or regions permits the user to control andconstrain any changes that may be allowed to the desired shape.

FIGS. 3 and 4 above describe exemplary uses of the system for portioningworkpieces to shape and weight, or to shape, weight, and size,respectively. Various alternative uses of the present system arepossible, as will be apparent to one skilled in the art. For example, inone embodiment, the system of the present invention may be used to cutworkpieces into a specific shape and size, regardless of weight, whileoptionally avoiding undesirable material, such as keel, defects, andvisible fat. Further alternatively or additionally, the system may beused to cut remaining trim from the portioning process into furtherdesired products, such as strips and nuggets. In any of the variousembodiments, workpieces are cut into portions having a specific orapproximate shape, while also meeting one or more other specificationsas defined by the user.

FIG. 9 is a flow chart illustrating the routine to be performed duringShape Scanner Mode, which is a special case of Shape Input Mode.Therefore, the flow chart of FIG. 9 generally replaces steps 24 and 25of FIG. 2. In step 90, using any suitable user interface, the userrequests to enter Shape Scanner Mode. (For example, by selecting the“Shape Scanner Mode” on-screen button on the monitor 20 b of thesystem.) In step 91, the user is prompted to place a reference shape,made of any suitable material, onto an infeed belt of the system. Thereference shape may be an actual product cut by scissors by the user, ormay be a template shape cut out from cardboard, or made of clay,Play-Doh®, etc. Referring to FIG. 1B, once the user places the referenceshape RS onto the conveyor, the scanner 16 scans in the reference shape(see step 92 of FIG. 9). Still referring to FIG. 9, in step 93, thesystem notifies the user that the reference shape has been scanned inand is ready to be edited or used for cutting. In step 94, it isdetermined whether the user has requested to edit the reference shape.If so, proceeding to step 95, the system permits the user to edit thereference shape, as previously described in reference to FIGS. 8A and8B, above. Then, in step 96, upon user confirmation, the reference shapeis saved into the system memory. Once the reference shape is saved, invarious exemplary embodiments, the system instantly returns to NormalOperation Mode to use the saved reference shape in all subsequentcutting operations.

As will be apparent from FIG. 2, the user can interrupt the normaloperation of the automatic portioning system 10 anytime to scan in andedit the desired shape template. The desired shape is stored into memoryand will be used to control the downstream cutting/portioning equipmentof the portioning system to cut the workpieces into the desired shape.In step 95 of FIG. 9, as before, the user may accent certain points orregions within the scanned-in shape for the purpose of controlling anychanges allowed to the reference shape.

Accordingly, the present invention offers various methods and systemsfor automatically portioning workpieces into a certain or approximateshape, while also satisfying one or more other specifications defined bythe user, such as weight and size. The final determination of the shapeto be cut from each workpiece is further constrained by user-set valuessuch as position offsets and avoidance areas (e.g., keel, bone, fat,etc.). Thus, in accordance with the present invention, a completelyautomatic shape cutting is possible, and further can be optimized, toprovide for efficient cutting.

In accordance with a further aspect of the present invention, it ispossible to consider the effect of meeting (or controlling)user-specified parameters on other parameters that are not directlycontrolled, prior to cutting. Specifically, the present inventionfurther offers a method that may be used where a workpiece is beingprocessed by cutting or trimming, and it is desired that the resultingcut or trimmed product have particular characteristics not directlycontrolled by the cutting or trimming process.

In many applications where a combination of two or more characteristics(or specifications) of the finished product are sought (e.g., shape,weight, length, width, etc.), it may be that one or more of thesecharacteristics are directly controllable, and others are indirectresults of the cutting or trimming process. For example, in trimming ofchicken breasts, the shape and weight of the resulting trimmed piece maybe directly controllable, as described above in reference to FIG. 3, butthe thickness of the resulting piece may not be directly controlled, andthus may vary amongst multiple final products.

According to a further aspect of the present invention, where one ormore characteristics cannot be directly controlled and yet are theresults of controlling the directly controllable characteristics, thedirectly controllable characteristics are selected so as to optimize theindirectly-controlled characteristics. Specifically, in circumstanceswhere more than one option exists for values of the directlycontrollable characteristics, and where a simulation can be done toassess the resulting indirectly-controlled characteristics prior toactually performing the cutting operations, then it is possible toachieve target values for all characteristics. The present inventionprovides a method of doing this, where the indirectly-controlledcharacteristics are measured and classified into one of severalcategories.

In the example of portioning chicken breasts, let the first step in theprocess be to capture a three-dimensional image of the chicken breastusing the scanner 16 connected to the processor 20, as described above.The processor 20 will then have stored in its memory a 3D model of thechicken breast that can subsequently be used to simulate the effects ofvarious cut patterns.

Assume that one set of acceptable target shape and weight is designatedas SW1 and a second set as SW2, and one acceptable thickness range isdesignated as T1 and a second as T2. Assume also that the followingthree combinations of shape and weight requirements and thickness rangesare acceptable in the finished cut product.

-   -   SW1+T1    -   SW1+T2    -   SW2+T2

According to one example, the method proceeds as follows:

-   -   First, using the 3D model in processor memory, the effects of        cutting to shape and weight requirements SW1 are simulated.    -   Second, using the new product boundary resulting from the        simulated cuts according to SW1, and referring again to the 3D        model, the thickness statistics (average thickness, for example)        within the boundary are calculated.    -   Third, if the thickness as simulated is within the limits of        range T1 or T2, then appropriate signals are generated to        actually perform the simulated cut pattern and classify/sort the        resulting cut product into a category corresponding to either        SW1+T1 or SW1+T2, as appropriate.    -   Fourth, if the simulated thickness does not fall within either        range T1 or T2, using the 3D model, the effects of cutting the        workpiece according to the shape and weight requirements SW2 are        simulated, and the thickness within the resulting boundary is        evaluated and compared to the allowable limits (for SW2 only        range T2 is acceptable). If the evaluated thickness is within        the range, signals are issued to perform the simulated cut        pattern according to SW2+T2.    -   Fifth, if neither cutting to requirements SW1 nor SW2 results in        a product within the acceptable thickness range(s), then no        solution exists.

FIG. 10 is a flow chart illustrating a general process of evaluatingwhat effects cutting a workpiece according to certain specificationswill have on the cut piece's other characteristics, which are notdirectly controlled by the cutting process, to ensure that the finalpiece will have desirable indirectly-controlled characteristics. In step100, a user requests to cut workpieces by directly controlling certainspecification(s) (e.g., shape, weight, etc.) so that they fall withinone of multiple acceptable categories, such as by ensuring that one ofmultiple specification requirements DS₁, DS₂, . . . or DS_(n) is met.Further, the user requests that the pieces cut to the specificationrequirements DS₁, DS₂, . . . or DS_(n) need to have one or moreresulting indirectly-controlled characteristic(s) (e.g., thickness),IS₁, IS₂, . . . or IS_(n).

Then, for each scanned workpiece (block 102), in block 104, cutting theworkpiece according to one or more of the directly-controlledspecifications (DS₁, DS₂, . . . or DS_(n)) is simulated, and theresulting indirectly-controlled specification(s) for each simulatedcutting is calculated. For example, cutting according to thespecification DS₁ is simulated, and the indirectly-controlledspecification (e.g., thickness) resulting from cutting to thespecification DS₁ is calculated. If an acceptable combination of DS₁,DS₂, . . . or DS_(n) and IS₁, IS₂, . . . or IS_(n) is found, then theacceptable combination may be selected as the combination according towhich the subsequent cut is to be performed. Various methods forselecting one combination are possible. For example, as with theprevious example, it is possible to continue the simulation andcalculation process until the first acceptable combination is found.Alternatively, a value function may be used to rank multiple alternativesolutions. According to this variation, cutting to each of the multiplespecification requirements (DS₁, DS₂, . . . or DS_(n), in this example)is simulated, and the resulting indirectly-controlled specification(s)(e.g., thickness) are calculated for each simulation and compared to theacceptable indirectly-controlled specification(s) (IS₁, IS₂, . . . orIS_(n)). If multiple acceptable combinations exist, a suitable valuefunction is used to select the most preferable combination.

After the acceptable, optimal combination of DS₁, DS₂, . . . or DS_(n)and IS₁, IS₂, . . . or IS_(n) is found, then proceeding to step 106, theportioning system is used to perform an actual cut according to theselected combination of the directly-controlled andindirectly-controlled specifications.

While the preferred embodiments of the invention have been illustratedand described, it will be appreciated that various changes can be madetherein without departing from the spirit and scope of the invention.

1. A method of portioning a workpiece into one or more pieces,comprising: (a) scanning a workpiece to obtain scanning information; (b)determining a cut path to portion a piece having a predefined shape andsatisfying one or more user-defined parameters by scaling up or down atemplate of the predefined shape until the one or more user-definedparameters are satisfied; and (c) portioning the workpiece according tothe determined cut path.
 2. The method of claim 1, wherein the one ormore user-defined parameters comprise a weight parameter, and step (b)comprises scaling up or down the template until the user-defined weightis achieved.
 3. The method of claim 1, wherein the one or moreuser-defined parameters comprise a size parameter, and step (b)comprises scaling up or down the template until the user-defined size isachieved.
 4. The method of claim 1, wherein step (b) of determining acut path comprises scaling up or down a template of the predefined shapeproportionately in both X and Y dimensions in X-Y coordinate space. 5.The method of claim 1, wherein the predefined shape is defined as apredefined shape range.
 6. The method of claim 1, wherein step (b) ofdetermining a cut path comprises scaling up or down a template of thepredefined shape while avoiding including undesirable material into thepiece to be portioned.
 7. The method of claim 1, wherein step (b) ofdetermining a cut path comprises scaling up or down a template of thepredefined shape by moving user-specified accent points.
 8. The methodof claim 1, further comprising performing, prior to step (a) of scanninga workpiece, the step of scanning a reference shape into which theworkpiece is to be portioned.
 9. The method of claim 8, furthercomprising performing, prior to step (a) of scanning a workpiece, thestep of permitting a user to edit the scanned-in reference shape.
 10. Asystem for portioning a workpiece into one or more pieces, comprising: aconveyor for carrying a workpiece to be portioned thereon; a scanner forscanning the workpiece; a cutter for portioning the workpiece; and aprocessor coupled to the conveyor, scanner, and cutter, the processorcomprising computer-executable instructions for performing the steps of:(a) controlling the scanner to scan the workpiece to obtain scanninginformation; (b) determining a cut path to portion a piece having apredefined shape and satisfying one or more user-defined parameters byscaling up or down a template of the predefined shape until the one ormore user-defined parameters are satisfied; and (c) controlling thecutter to portion the workpiece according to the determined cut path.11. The system of claim 10, wherein the one or more user-definedparameters comprise a weight parameter, and step (b) comprises scalingup or down the template until the user-defined weight is achieved. 12.The system of claim 11, wherein the weight of a piece to be portionedfrom the workpiece is calculated based on a volume of the piece asdetermined from the scanning information and a known density of theworkpiece.
 13. The system of claim 12, wherein the system furthercomprises a weighing station downstream from the cutter to weigh a pieceportioned from the workpiece, and the processor comprisescomputer-executable instructions for performing a further step ofupdating the density of the workpiece based on the actual weight of thepiece portioned from the workpiece.
 14. The system of claim 10, whereinstep (b) of determining a cut path comprises scaling up or down atemplate of the predefined shape proportionately in both X and Ydimensions in X-Y coordinate space.
 15. The system of claim 10, furthercomprising a user interface system that permits a user to switch betweennormal production mode, in which workpieces are automatically scannedand portioned, and shape scanner mode, in which a user places areference shape on the conveyor to be scanned by the scanner.
 16. Amethod of automatically portioning a workpiece into one or more pieces,comprising: (a) scanning a reference shape; (b) retaining datapertaining to the reference shape; (c) determining a cut path to portionthe workpiece into one or more pieces having the reference shape; and(d) portioning the workpiece according to the determined cut path. 17.The method of claim 16, wherein the reference shape may be formed of aworkpiece, paper, or clay-like material.
 18. The method of claim 16,wherein the reference shape comprises a workpiece that has been cut tothe reference shape by hand.
 19. The method of claim 16, furthercomprising performing, prior to step (a), the step of prompting a userto place a reference shape in position to be scanned.
 20. The method ofclaim 16, further comprising performing, after step (a) and prior tostep (b), the step of permitting a user to edit the scanned-in referenceshape.
 21. The method of claim 16, wherein step (c) of determining a cutpath comprises scaling up or down the reference shape on the workpieceuntil a predefined weight or weight range is achieved.
 22. The method ofclaim 16, wherein step (c) of determining a cut path comprises scalingup or down the reference shape while avoiding including undesirablematerial into the piece to be portioned.
 23. The method of claim 16,wherein step (c) of determining a cut path comprises scaling up or downthe reference shape by moving user-specified accent points.
 24. A systemfor portioning a workpiece into one or more pieces, comprising: ascanner for scanning the workpiece; a cutter for portioning theworkpiece; and a processor coupled to the scanner and cutter, theprocessor comprising computer-executable instructions for performing thesteps of: (a) prompting a user to place a reference shape into which aworkpiece is to be portioned in position to be scanned; (b) controllingthe scanner to scan the reference shape; (c) recording the referenceshape; (d) determining a cut path to portion the workpiece into one ormore pieces having the reference shape; and (e) controlling the cutterto portion the workpiece according to the determined cut path.
 25. Thesystem of claim 24, further comprising a conveyor for carrying theworkpiece to be portioned as well as during portioning.
 26. The systemof claim 24, wherein step (d) of determining a cut path comprisesscaling up or down the reference shape on the workpiece until apredefined weight or weight range is achieved.
 27. The system of claim24, wherein the processor further comprises computer-executableinstructions for performing, after step (b) and prior to step (c), thestep of permitting a user to edit the scanned-in reference shape. 28.The system of claim 24, further comprising a user interface system thatpermits a user to switch between normal production mode, in whichworkpieces are automatically scanned and portioned, and shape scannermode, in which a user places a reference shape in position to be scannedby the scanner.
 29. A method of automatically portioning a workpieceinto one or more pieces, comprising: (a) receiving multiple acceptablecombinations of one or more directly-controlled specifications and oneor more indirectly-controlled specifications of a final piece to beportioned from each workpiece; (b) scanning a workpiece to obtainscanning information; (c) simulating portioning the workpiece accordingto one or more directly-controlled specifications and calculating theone or more indirectly-controlled specifications of the final piece tobe portioned according to the one or more directly-controlledspecifications; (d) determining an acceptable combination of the one ormore directly-controlled specifications and the one or moreindirectly-controlled specifications; (e) portioning the workpieceaccording to the combination of specifications as determined in step (d)above.
 30. The method of claim 29, wherein step (c) is repeated for eachof all multiple acceptable combinations, and step (d) comprisesselecting an optimal combination from the multiple acceptablecombinations according to a value function that ranks the multipleacceptable combinations.
 31. The method of claim 29, wherein the one ormore directly-controlled specifications comprise the shape and weight ofthe pieces to be portioned from the workpiece, and the one or moreindirectly-controlled specifications comprise the thickness of thepieces to be portioned from the workpiece.